Bio-sourced transparent and ductile polycarbonate blends

ABSTRACT

Bio-sourced polycarbonate compositions comprising, for example, a styrene-ethylene-butadiene-styrene polymer are disclosed. These polycarbonate compositions can exhibit improved ductility and/or ageing resistance compared to conventional polycarbonate compositions. Methods for the preparation of the bio-sourced polycarbonate compositions are also disclosed.

BACKGROUND

1. Technical Field

The present disclosure relates to biosourced polycarbonate, and specifically to biosourced polycarbonate compositions having improved ductility and aging resistance.

2. Technical Background

Polymers based on aliphatic diols derived from biologically-based sources are of great interest in the plastics industry and in manufacturing, for the preparation of materials and products that can be derived from inexpensive, renewable sources and that also are biodegradable, and thereby have a low net environmental impact. Of particular interest are polymers based on isosorbides. These materials are of great interest to the chemical industry, and in particular in the production of polymeric materials such as polycarbonates, because such aliphatic diols can be produced from renewable resources rather than from the petroleum feedstocks used to prepare other monomers useful in the production of polycarbonates, such as bisphenol monomers. This bio-sourced polycarbonate (PC) can have high tensile modulus, scratch resistance, and can be processed at 250° C.

For practical applications, polycarbonate incorporating isosorbide needs a balance of properties to be useful. Polycarbonates in general should have sufficiently high molecular weight for desirable mechanical properties, and sufficiently low glass transition temperatures and flow to be useful in molding and extrusion applications. While bio-sourced polycarbonate can provide improved properties over conventional petroleum based polycarbonate materials, existing bio-sourced polycarbonate materials exhibit poor ductility, heat and hydro aging resistance, and UV aging resistance.

Thus, there remains a continuing desire in the industry for continued improvement in bio-sourced polycarbonate materials, including a need for polycarbonate compositions having improved ductility, heat and hydro aging resistance and UV aging resistance. These needs and other needs are satisfied by the compositions and methods of the present disclosure.

SUMMARY

In accordance with the purpose(s) of the invention, as embodied and broadly described herein, this disclosure, in one aspect, relates to bio-sourced polycarbonate, and specifically to bio-sourced polycarbonate composition having improved ductility and aging resistance.

In one aspect, the present disclosure provides a bio-sourced polycarbonate composition comprising a styrene-ethylene-butadiene-styrene polymer.

In another aspect, the present disclosure provides a method for preparing a bio-sourced polycarbonate composition, the method comprising contacting an isosorbide-bis-phenol A polycarbonate-C36 diacid terpolymer (Iso ter PC) with a styrene-ethylene-butadiene-styrene (SEBS) polymer.

BRIEF DESCRIPTION OF THE FIGURES

The accompanying figures, which are incorporated in and constitute a part of this specification, illustrate several aspects and together with the description serve to explain the principles of the invention.

FIG. 1 is a graph illustrating the normalized change in notched izod impact (NII) strength of Iso65 ter PC and BPAPC with addition of 6% SEBS, in accordance with various aspects of the present invention.

FIG. 2 is a graph illustrating the effect of impact modifiers on color shift of samples exposed to heat, hydro aging, and UV aging, in accordance with various aspects of the present invention.

FIG. 3 illustrates the groove height observed during scratch resistance measurements, in accordance with various aspects of the present invention.

Additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or can be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

DESCRIPTION

The present invention can be understood more readily by reference to the following detailed description of the invention and the Examples included therein.

Before the present compounds, compositions, articles, systems, devices, and/or methods are disclosed and described, it is to be understood that they are not limited to specific synthetic methods unless otherwise specified, or to particular reagents unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, example methods and materials are now described.

All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited.

DEFINITIONS

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, example methods and materials are now described.

As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a ketone” includes mixtures of two or more ketones.

Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. For example, if the value “10” is disclosed, then “about 10” is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

As used herein, the terms “optional” or “optionally” means that the subsequently described event or circumstance can or can not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not. For example, the phrase “optionally substituted alkyl” means that the alkyl group can or can not be substituted and that the description includes both substituted and unsubstituted alkyl groups.

Disclosed are the components to be used to prepare the compositions of the invention as well as the compositions themselves to be used within the methods disclosed herein. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these materials are disclosed that while specific reference of each various individual and collective combinations and permutation of these compounds can not be explicitly disclosed, each is specifically contemplated and described herein. For example, if a particular compound is disclosed and discussed and a number of modifications that can be made to a number of molecules including the compounds are discussed, specifically contemplated is each and every combination and permutation of the compound and the modifications that are possible unless specifically indicated to the contrary. Thus, if a class of molecules A, B, and C are disclosed as well as a class of molecules D, E, and F and an example of a combination molecule, A-D is disclosed, then even if each is not individually recited each is individually and collectively contemplated meaning combinations, A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are considered disclosed. Likewise, any subset or combination of these is also disclosed. Thus, for example, the sub-group of A-E, B-F, and C-E would be considered disclosed. This concept applies to all aspects of this application including, but not limited to, steps in methods of making and using the compositions of the invention. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific aspect or combination of aspects of the methods of the invention.

References in the specification and concluding claims to parts by weight, of a particular element or component in a composition or article, denotes the weight relationship between the element or component and any other elements or components in the composition or article for which a part by weight is expressed. Thus, in a compound containing 2 parts by weight of component X and 5 parts by weight component Y, X and Y are present at a weight ratio of 2:5, and are present in such ratio regardless of whether additional components are contained in the compound.

A weight percent of a component, unless specifically stated to the contrary, is based on the total weight of the formulation or composition in which the component is included.

A residue of a chemical species, as used in the specification and concluding claims, refers to the moiety that is the resulting product of the chemical species in a particular reaction scheme or subsequent formulation or chemical product, regardless of whether the moiety is actually obtained from the chemical species. Thus, an ethylene glycol residue in a polyester refers to one or more —OCH₂CH₂O— units in the polyester, regardless of whether ethylene glycol was used to prepare the polyester. Similarly, a sebacic acid residue in a polyester refers to one or more —CO(CH₂)₈CO— moieties in the polyester, regardless of whether the residue is obtained by reacting sebacic acid or an ester thereof to obtain the polyester.

The term “alkyl group” as used herein is a branched or unbranched saturated hydrocarbon group of 1 to 24 carbon atoms, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, t-butyl, pentyl, hexyl, heptyl, octyl, decyl, tetradecyl, hexadecyl, eicosyl, tetracosyl and the like. A “lower alkyl” group is an alkyl group containing from one to six carbon atoms.

The term “alkoxy” as used herein is an alkyl group bound through a single, terminal ether linkage; that is, an “alkoxy” group can be defined as —OR where R is alkyl as defined above. A “lower alkoxy” group is an alkoxy group containing from one to six carbon atoms.

The term “alkenyl group” as used herein is a hydrocarbon group of from 2 to 24 carbon atoms and structural formula containing at least one carbon-carbon double bond. Asymmetric structures such as (AB)C═C(CD) are intended to include both the E and Z isomers. This can be presumed in structural formulae herein wherein an asymmetric alkene is present, or it can be explicitly indicated by the bond symbol C.

The term “alkynyl group” as used herein is a hydrocarbon group of 2 to 24 carbon atoms and a structural formula containing at least one carbon-carbon triple bond.

The term “aryl group” as used herein is any carbon-based aromatic group including, but not limited to, benzene, naphthalene, etc. The term “aromatic” also includes “heteroaryl group,” which is defined as an aromatic group that has at least one heteroatom incorporated within the ring of the aromatic group. Examples of heteroatoms include, but are not limited to, nitrogen, oxygen, sulfur, and phosphorus. The aryl group can be substituted or unsubstituted. The aryl group can be substituted with one or more groups including, but not limited to, alkyl, alkynyl, alkenyl, aryl, halide, nitro, amino, ester, ketone, aldehyde, hydroxy, carboxylic acid, or alkoxy.

The term “cycloalkyl group” as used herein is a non-aromatic carbon-based ring composed of at least three carbon atoms. Examples of cycloalkyl groups include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, etc. The term “heterocycloalkyl group” is a cycloalkyl group as defined above where at least one of the carbon atoms of the ring is substituted with a heteroatom such as, but not limited to, nitrogen, oxygen, sulphur, or phosphorus.

The term “aralkyl” as used herein is an aryl group having an alkyl, alkynyl, or alkenyl group as defined above attached to the aromatic group. An example of an aralkyl group is a benzyl group.

The term “hydroxyalkyl group” as used herein is an alkyl, alkenyl, alkynyl, aryl, aralkyl, cycloalkyl, halogenated alkyl, or heterocycloalkyl group described above that has at least one hydrogen atom substituted with a hydroxyl group.

The term “alkoxyalkyl group” is defined as an alkyl, alkenyl, alkynyl, aryl, aralkyl, cycloalkyl, halogenated alkyl, or heterocycloalkyl group described above that has at least one hydrogen atom substituted with an alkoxy group described above.

The term “ester” as used herein is represented by the formula —C(O)OA, where A can be an alkyl, halogenated alkyl, alkenyl, alkynyl, aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, or heterocycloalkenyl group described above.

The term “carbonate group” as used herein is represented by the formula —OC(O)OR, where R can be hydrogen, an alkyl, alkenyl, alkynyl, aryl, aralkyl, cycloalkyl, halogenated alkyl, or heterocycloalkyl group described above.

The term “carboxylic acid” as used herein is represented by the formula —C(O)OH.

The term “aldehyde” as used herein is represented by the formula —C(O)H.

The term “keto group” as used herein is represented by the formula —C(O)R, where R is an alkyl, alkenyl, alkynyl, aryl, aralkyl, cycloalkyl, halogenated alkyl, or heterocycloalkyl group described above.

The term “carbonyl group” as used herein is represented by the formula C═O.

The term “ether” as used herein is represented by the formula AOA¹, where A and A¹ can be, independently, an alkyl, halogenated alkyl, alkenyl, alkynyl, aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, or heterocycloalkenyl group described above.

The term “sulfo-oxo group” as used herein is represented by the formulas —S(O)₂R, —OS(O)₂R, or, —OS(O)₂OR, where R can be hydrogen, an alkyl, alkenyl, alkynyl, aryl, aralkyl, cycloalkyl, halogenated alkyl, or heterocycloalkyl group described above.

Unless specifically stated to the contrary, terms for components and materials used throughout the specification are listed in Table 1, below, together with a description and source.

TABLE 1 Raw materials Used. Component Supplier Description Iso65 ter PC SABIC Isosorbide-bisphenol A polycarbonate-C36 diacid Innovative terpolymer in the ratio of 65/28/7. Plastics Iso80 ter PC SABIC Isosorbide-bisphenol A polycarbonate-C36 diacid Innovative terpolymer in the ratio of 80/13/7. Plastics BPAPC (PC SABIC BPA polycarbonate resin made by an interfacial process 105) Innovative with an MVR at 300° C./1.2 kg, of 5.1-6.9 g/10 min Plastics SEBS with 13% Kraton Polymers Styrene-Ethylene-Butadiene-Styrene (SEBS) elastomer with styrene (S1) 13% styrene, grade name KRATON ® G 1657M SEBS with 33% Kraton Polymers Styrene-Ethylene-Butadiene-Styrene (SEBS) elastomer with styrene (S2) 33% styrene, grade name KRATON ® G 1651M SEBS with 67% Asahi Kasei Styrene-Ethylene-Butadiene-Styrene (SEBS) elastomer with styrene (S3) Chemicals 67% styrene, grade name TUFTEC ® H1043 Corporation MBS Rohm & Haas Nominal 75-82 wt. % butadiene core with a balance styrene-methyl methacrylate shell, available under the tradename EXL-2691-A. ADR 4368F Aldrich Styrenic epoxy resin (Epoxy Resin) Chemicals

Each of the materials disclosed herein are either commercially available and/or the methods for the production thereof are known to those of skill in the art.

It is understood that the compositions disclosed herein have certain functions. Disclosed herein are certain structural requirements for performing the disclosed functions, and it is understood that there are a variety of structures that can perform the same function that are related to the disclosed structures, and that these structures will typically achieve the same result.

As briefly described above, the present disclosure provides a bio-sourced polymer, such as, for example, a bio-sourced polycarbonate having improved ductility, heat and aging resistance, and UV resistance. In various aspects, the inventive polymer system exhibits at least one of improved ductility, improved heat aging resistance, improved hydro aging resistance, improved UV aging resistance, or a combination thereof. In another aspect, the inventive polymer system maintains good transparency, scratch resistance, tensile properties, heat properties, or a combination thereof.

Demand for ductile thermoplastic materials is currently satisfied by petroleum based polycarbonates, but concerns regarding availability and cost of crude oil and environmental emissions have spurred growing interest in renewable bio-sourced polymer materials. Recent developments have allowed the production of polycarbonate materials from natural, starch-based vegetation. For example, bio-sourced polymers can be manufactured from corn, potatoes, sugarcane, and wheat. In one aspect, a bio-sourced polycarbonate can be produced from an isosorbide monomer. In another aspect, such an isosorbide monomer can be sourced from corn.

Bio-sourced polycarbonate (PC) can have a higher tensile modulus, higher tensile strength, and scratch resistance than conventional petroleum based polycarbonate. Bio-sourced polycarbonate can also have a higher melt flow rate (MVR) and lower glass transition temperature (T_(g)) than petroleum based polycarbonate, enabling processing at lower temperatures, for example, about 250° C. Such lower processing temperatures can result in reduced energy consumption during manufacture. While these properties are advantageous for a bio-sourced polymer, the produced polymer can exhibit poor ductility and impact strength.

In one aspect, the present disclosure provides copolymers and/or terpolymers comprising an isosorbide monomer. In one aspect, each of the compositions and methods described herein, unless specifically stated to the contrary, are directed to an Isosorbide BPAPC-C36 diacid (65/28/7) terpolymer (“Iso65 ter PC”). In other aspects, the compositions and methods described herein can relate to other isosorbide based polycarbonate materials, and the present invention is not intended to be limited to an Iso ter PC material. In still other aspects, the compositions described herein can comprise an isosorbide based polycarbonate material, such as Iso ter PC, and one or more other polycarbonate materials that can be bio-sourced, non bio-sourced, or a combination thereof.

The term “Iso ter PC” as used herein is intended to generically represent a terpolymer comprising and/or prepared from an isosorbide, bis-phenol A polycarbonate, and a C36 diacid. References to Iso65 ter PC, Iso80 ter PC, and the like are intended to refer to terpolymers comprising various concentrations of isosorbide.

Improvements in ductility with bio-sourced polycarbonates can be achieved by blending with a butadiene core/styrene methyl methacrylate shell (MBS) modifier. These systems, however, still suffer from poor transparency, scratch resistance, and aging (heat & hydro, and UV) resistance.

In one aspect, the inventive polymer system comprises a polycarbonate material and an elastomer. In another aspect, the inventive polymer system comprises a bio-sourced polycarbonate material and an elastomer. In yet another aspect, the inventive polymer system comprises a polycarbonate material and a saturated elastomer.

In various aspects, the inventive polymer system can improve aging resistance by utilizing an elastomer modifier, such as, for example a saturated elastomer, instead of an MBS modifier. In one aspect, the inventive polymer system comprises a styrene-ethylene-butadiene-styrene (SEBS) elastomer instead of a conventional MBS modifier. In various aspects, the use of a SEBS modifier can provide improved resistance to heat & hydro aging, improved resistance to UV aging, together with good retention of transparency and scratch resistance properties.

In one aspect, the present disclosure provides an isosorbide-bisphenol A polycarbonate-C36 diacid ter polymer in the ratios of 65/28/7 (Iso65-ter-PC), 80/13/7 (Iso80-ter-PC) with bio-contents of 59.4% and 73.1%, respectively (generically Iso ter PC). In another aspect, the present disclosure provides blends of Iso ter PC resins and a SEBS impact modifier.

Polycarbonate

In one aspect, the present disclosure provides an isosorbide-based polycarbonate. In various aspects, the isosorbide-based polycarbonates can have useful mechanical properties such as impact strength and transparency as well as a high content of biologically derived materials (i.e., polymer precursors that are derived from sustainable biological sources such as plants). In other aspects, the isosorbide-based polycarbonates can optionally have low background color, good UV stability, and good molecular weight (Mw) stability.

As used herein, the term “polycarbonate” includes homopolycarbonates and copolycarbonates have repeating structural carbonate units. In one aspect, a polycarbonate can comprise any polycarbonate material or mixture of materials as recited in U.S. Pat. No. 7,786,246, which is hereby incorporated in its entirety for the specific purpose of disclosing various polycarbonate compositions and methods.

In one aspect, a polycarbonate, as disclosed herein, can be an aliphatic-diol based polycarbonate. In another aspect, a polycarbonate can comprise a carbonate unit derived from a dihydroxy compound, such as for example a bisphenol that differs from the aliphatic diol.

In one aspect, non-limiting examples of suitable bisphenol compounds include the following: 4,4′-dihydroxybiphenyl, 1,6-dihydroxynaphthalene, 2,6-dihydroxynaphthalene, bis(4-hydroxyphenyl)methane, bis(4-hydroxyphenyl)diphenylmethane, bis(4-hydroxyphenyl)-1-naphthylmethane, 1,2-bis(4-hydroxyphenyl)ethane, 1,1-bis(4-hydroxyphenyl)-1-phenylethane, 2-(4-hydroxyphenyl)-2-(3-hydroxyphenyl)propane, bis(4-hydroxyphenyl)phenylmethane, 2,2-bis(4-hydroxy-3-bromophenyl)propane, 1,1-bis(hydroxyphenyl)cyclopentane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxy-3 methylphenyl)cyclohexane 1,1-bis(4-hydroxyphenyl)isobutene, 1,1-bis(4-hydroxyphenyl)cyclododecane, trans-2,3-bis(4-hydroxyphenyl)-2-butene, 2,2-bis(4-hydroxyphenyl)adamantine, (alpha,alpha′-bis(4-hydroxyphenyl)toluene, bis(4-hydroxyphenyl)acetonitrile, 2,2-bis(3-methyl-4-hydroxyphenyl)propane, 2,2-bis(3-ethyl-4-hydroxyphenyl)propane, 2,2-bis(3-n-propyl-4-hydroxyphenyl)propane, 2,2-bis(3-isopropyl-4-hydroxyphenyl)propane, 2,2-bis(3-sec-butyl-4-hydroxyphenyl)propane, 2,2-bis(3-t-butyl-4-hydroxyphenyl)propane, 2,2-bis(3-cyclohexyl-4-hydroxyphenyl)propane, 2,2-bis(3-allyl-4-hydroxyphenyl)propane, 2,2-bis(3-methoxy-4-hydroxyphenyl)propane, 2,2-bis(4-hydroxyphenyl)hexafluoropropane, 1,1-dichloro-2,2-bis(4-hydroxyphenyl)ethylene, 1,1-dibromo-2,2-bis(4-hydroxyphenyl)ethylene, 1,1-dichloro-2,2-bis(5-phenoxy-4-hydroxyphenyl)ethylene, 4,4′-dihydroxybenzophenone, 3,3-bis(4-hydroxyphenyl)-2-butanone, 1,6-bis(4-hydroxyphenyl)-1,6-hexanedione, ethylene glycol bis(4-hydroxyphenyl)ether, bis(4-hydroxyphenyl)ether, bis(4-hydroxyphenyl)sulfide, bis(4-hydroxyphenyl)sulfoxide, bis(4-hydroxyphenyl)sulfone, 9,9-bis(4-hydroxyphenyl)fluorene, 2,7-dihydroxypyrene, 6,6′-dihydroxy-3,3,3′,3′-tetramethylspiro(bis)indane (“spirobiindane bisphenol”), 3,3-bis(4-hydroxyphenyl)phthalide, 2,6-dihydroxydibenzo-p-dioxin, 2,6-dihydroxythianthrene, 2,7-dihydroxyphenoxathin, 2,7-dihydroxy-9,10-dimethylphenazine, 3,6-dihydroxydibenzofuran, 3,6-dihydroxydibenzothiophene, and 2,7-dihydroxycarbazole, and the like, as well as combinations comprising at least one of the foregoing dihydroxy aromatic compounds.

In another aspect, exemplary bisphenol compounds can comprise 1,1-bis(4-hydroxyphenyl)methane, 1,1-bis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxyphenyl)propane (hereinafter “bisphenol A” or “BPA”), 2,2-bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)octane, 1,1-bis(4-hydroxyphenyl)propane, 1,1-bis(4-hydroxyphenyl)n-butane, 2,2-bis(4-hydroxy-1-methylphenyl)propane, 1,1-bis(4-hydroxy-t-butylphenyl)propane, 3,3-bis(4-hydroxyphenyl)phthalimidine, 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine (“PPPBP”), and 9,9-bis(4-hydroxyphenyl)fluorene. Combinations comprising at least one dihydroxy aromatic compound can also be used. In another aspect, other types of diols can be present in the isosorbide-based polycarbonate.

In yet another aspect, polycarbonates with branching groups are can be useful, provided that such branching does not significantly adversely affect desired properties of the polycarbonate. Branched polycarbonate blocks can be prepared by adding a branching agent during polymerization. These branching agents include polyfunctional organic compounds containing at least three functional groups selected from hydroxyl, carboxyl, carboxylic anhydride, haloformyl, and mixtures of the foregoing functional groups. Specific examples include trimellitic acid, trimellitic anhydride, trimellitic trichloride, tris-p-hydroxy phenyl ethane, isatin-bis-phenol, tris-phenol TC (1,3,5-tris((p-hydroxyphenyl)isopropyl)benzene), tris-phenol PA (4(4(1,1-bis(p-hydroxyphenyl)-ethyl)alpha,alpha-dimethylbenzyl)phenol), 4-chloroformyl phthalic anhydride, trimesic acid, and benzophenone tetracarboxylic acid. In one aspect, a branching agent can be added at a level of about 0.05 to about 2.0 wt %. In still another aspect, mixtures comprising linear polycarbonates and branched polycarbonates can be used.

Polycarbonates, including isosorbide-based polyester-polycarbonate, can comprise copolymers comprising carbonate units and other types of polymer units, including ester units, and combinations comprising at least one of homopolycarbonates and copolycarbonates. An exemplary polycarbonate copolymer of this type is a polyester carbonate, also known as a polyester-polycarbonate. Such copolymers further contain carbonate units derived from oligomeric ester-containing dihydroxy compounds (also referred to herein as hydroxy end-capped oligomeric acrylate esters).

In one aspect, an aliphatic-based polycarbonate comprises aliphatic units that are either aliphatic carbonate units derived from aliphatic diols, or a combination of aliphatic ester units derived from aliphatic diacids having greater than 13 carbons, in combination with isosorbide and aliphatic diols having greater than 13 carbons. Specifically, anisosorbide-based polycarbonate is an isosorbide-based copolycarbonate comprising an additional aliphatic carbonate unit derived from an aliphatic diol of greater than 13 carbons; or the isosorbide-based polycarbonate is an isosorbide-based polyester-polycarbonate comprising an ester unit.

In one aspect, the relative amount of each type of carbonate and/or ester unit present in an isosorbide-based polycarbonate can depend on the desired properties of the copolymer. In one aspect, the isosorbide-based polycarbonate or polyester-polycarbonate can comprise from about 55 mol % to 97.5 mol %, from about 60 mol % to about 95 mol %, or from about 65 mol % to about 90 mol % of isosorbide units.

In various aspects, the polycarbonate material of the present disclosure can comprise any suitable concentration of bio-sourced material. In one aspect, the polycarbonate of the present disclosure comprises from about 10 wt. % to about 90 wt. %, for example, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90 wt. % of bio-sourced material. In another aspect, the polycarbonate of the present disclosure comprises from about 50 wt. % to about 80 wt. %, for example, about 50, 52, 54, 56, 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78, or 80 wt. % of bio-sourced material. In another aspect, the polycarbonate of the present disclosure comprises at least about 50 wt. %, for example, about 50, 52, 54, 56, 58, 60, 62, 64, 66, 68, 70, 72, 74, or greater wt. %; or at least about 70 wt. %, for example, about 70, 72, 74, 76, or 80 wt. % of bio-sourced material. In still other aspects, the polycarbonate material of the present disclosure can comprise less than about 10 wt. % or greater than about 90 wt. % of bio-sourced material and the present disclosure is not intended to be limited to any particular concentration of bio-sourced material.

In one aspect, the molecular weight of any particular polycarbonate, including the an isosorbide-based polycarbonate, can be determined by, for example, gel permeation chromatography using universal calibration methods based on polystyrene (PS) standards. Generally polycarbonates can have a weight average molecular weight (Mw), of greater than about 5,000 g/mol based on PS standards. In one aspect, the isosorbide-based polycarbonates can have an Mw of greater than or equal to about 39,000 g/mol, based on PS standards. In another aspect, the isosorbide-based polycarbonate (including isosorbide-based polyester-polycarbonate) has an Mw based on PS standards of 39,000 to 100,000 g/mol, specifically 40,000 to 90,000 g/mol, more specifically 40,000 to 80,000 g/mol, and still more specifically 40,000 to 70,000 g/mol. In another aspect, the isosorbide-based polycarbonate has an Mw based on polycarbonate (PC) standards of 20,000 to 70,000 g/mol, specifically 21,000 to 65,000 g/mol, more specifically 22,000 to 60,000 g/mol, and still more specifically 25,000 to 60,000 g/mol.

In an aspect, the isosorbide-based polycarbonate has a number averaged molecular weight (Mn) based on PS standards of 15,000 to 65,000 g/mol, specifically 16,000 to 60,000 g/mol, more specifically 17,000 to 55,000 g/mol, and still more specifically 18,000 to 50,000 g/mol. In one aspect, the polydispersity (Mw/Mn) for isosorbide-based polycarbonate is less than or equal to 3, specifically less than or equal to 2.5, more specifically less than or equal to 2.3. In a specific aspect, the polydispersity is 2.0 to 2.3.

Molecular weight (Mw and Mn) as described herein, and polydispersity as calculated therefrom, can be determined using gel permeation chromatography (GPC), using a crosslinked styrene-divinylbenzene column, and either PS or PC standards as specified. GPC samples can be prepared in a solvent such as methylene chloride or chloroform at a concentration of about 1 mg/ml, and can be eluted at a flow rate of about 0.2 to 1.0 ml/min.

In one aspect, the glass transition temperature (T_(g)) of an isosorbide-based polycarbonate can be less than or equal to 135° C. In another aspect, the glass transition temperature of an isosorbide-based polycarbonate can be from about 85° C. to about 130° C., from about 90° C. to about 130° C., from about 90° C. to about 125° C., or from about 90° C. to about 120° C.

In another aspect, polycarbonates, such as, for example, the isosorbide-based polycarbonates disclosed herein, can have a melt volume ratio (MVR) of about 0.5 to about 80 cm³/10 minutes, or from about 2 to about 40 cm³/10 minutes, measured at 250° C. under a load of 5 kg according to ASTM D1238-04. In other aspects, a polycarbonate can have a melt volume ratio of less than about 0.5 or greater than about 80 cm³/10 minutes, and the present invention is not intended to be limited to any particular melt volume ratio.

In one aspect, polycarbonates can be manufactured using an interfacial phase transfer process or melt polymerization. Although the reaction conditions for interfacial polymerization can vary, an exemplary process generally involves dissolving or dispersing a dihydric phenol reactant in aqueous caustic soda or potash, adding the resulting mixture to a water-immiscible solvent medium such as for example methylene chloride, and contacting the reactants with a carbonate precursor (such as phosgene) in the presence of a catalyst such as, for example, triethylamine or a phase transfer catalyst salt, under controlled pH conditions of, for example, from about 8 to about 10.

The isosorbide-based polycarbonate or polyester-polycarbonate can, in various aspects, be prepared by a melt polymerization process. Generally, in the melt polymerization process, polycarbonates are prepared by co-reacting, in a molten state, the dihydroxy reactant(s) (i.e., isosorbide, aliphatic diol and/or aliphatic diacid, and any additional dihydroxy compound) and a diaryl carbonate ester, such as diphenyl carbonate, or more specifically in an aspect, an activated carbonate such as bis(methyl salicyl)carbonate, in the presence of a transesterification catalyst. The reaction can be carried out in typical polymerization equipment, such as one or more continuously stirred reactors (CSTRs), plug flow reactors, wire wetting fall polymerizers, free fall polymerizers, wiped film polymerizers, BANBURY® mixers, single or twin screw extruders, or combinations of the foregoing. In one aspect, volatile monohydric phenol can be removed from the molten reactants by distillation and the polymer is isolated as a molten residue. In another aspect, a useful melt process for making polycarbonates utilizes a diaryl carbonate ester having electron-withdrawing substituents on the aryls. Examples of specifically useful diaryl carbonate esters with electron withdrawing substituents include bis(4-nitrophenyl)carbonate, bis(2-chlorophenyl)carbonate, bis(4-chlorophenyl)carbonate, bis(methyl salicyl)carbonate, bis(4-methylcarboxylphenyl)carbonate, bis(2-acetylphenyl)carboxylate, bis(4-acetylphenyl)carboxylate, or a combination comprising at least one of the foregoing.

The melt polymerization can include a transesterification catalyst comprising a first catalyst, also referred to herein as an alpha catalyst, comprising a metal cation and an anion. In an aspect, the cation is an alkali or alkaline earth metal comprising Li, Na, K, Cs, Rb, Mg, Ca, Ba, Sr, or a combination comprising at least one of the foregoing. The anion is hydroxide (OH⁻), superoxide (O²⁻), thiolate (HS), sulfide (S²⁻), a C₁₋₂₀ alkoxide, a C₆₋₂₀ aryloxide, a C₁₋₂₀ carboxylate, a phosphate including biphosphate, a C₁₋₂₀ phosphonate, a sulfate including bisulfate, sulfites including bisulfites and metabisulfites, a C₁₋₂₀ sulfonate, a carbonate including bicarbonate, or a combination comprising at least one of the foregoing. In another aspect, salts of an organic acid comprising both alkaline earth metal ions and alkali metal ions can also be used. Salts of organic acids useful as catalysts are illustrated by alkali metal and alkaline earth metal salts of formic acid, acetic acid, stearic acid and ethyelenediamine tetraacetic acid. The catalyst can also comprise the salt of a non-volatile inorganic acid. By “nonvolatile”, it is meant that the referenced compounds have no appreciable vapor pressure at ambient temperature and pressure. In particular, these compounds are not volatile at temperatures at which melt polymerizations of polycarbonate are typically conducted. The salts of nonvolatile acids are alkali metal salts of phosphites; alkaline earth metal salts of phosphites; alkali metal salts of phosphates; and alkaline earth metal salts of phosphates. Exemplary transesterification catalysts include, lithium hydroxide, sodium hydroxide, potassium hydroxide, cesium hydroxide, magnesium hydroxide, calcium hydroxide, barium hydroxide, lithium formate, sodium formate, potassium formate, cesium formate, lithium acetate, sodium acetate, potassium acetate, lithium carbonate, sodium carbonate, potassium carbonate, lithium methoxide, sodium methoxide, potassium methoxide, lithium ethoxide, sodium ethoxide, potassium ethoxide, lithium phenoxide, sodium phenoxide, potassium phenoxide, sodium sulfate, potassium sulfate, NaH₂PO₃, NaH₂PO₄, Na₂H₂PO₃, KH₂PO₄, CsH₂PO₄, Cs₂H₂PO₄, Na₂SO₃, Na₂S₂O₅, sodium mesylate, potassium mesylate, sodium tosylate, potassium tosylate, magnesium disodium ethylenediamine tetraacetate (EDTA magnesium disodium salt), or a combination comprising at least one of the foregoing. It will be understood that the foregoing list is exemplary and should not be considered as limited thereto. In one aspect, the transesterification catalyst is an alpha catalyst comprising an alkali or alkaline earth salt. In an exemplary aspect, the transesterification catalyst comprising sodium hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate, sodium methoxide, potassium methoxide, NaH₂PO₄, or a combination comprising at least one of the foregoing.

The amount of alpha catalyst can vary widely according to the conditions of the melt polymerization, and can be about 0.001 to about 500 μmol. In an aspect, the amount of alpha catalyst can be about 0.01 to about 20 μmol, specifically about 0.1 to about 10 μmol, more specifically about 0.5 to about 9 μmol, and still more specifically about 1 to about 7 μmol, per mole of aliphatic diol and any other dihydroxy compound present in the melt polymerization.

In another aspect, a second transesterification catalyst, also referred to herein as a beta catalyst, can optionally be included in the melt polymerization process, provided that the inclusion of such a second transesterification catalyst does not significantly adversely affect the desirable properties of the isosorbide-based polycarbonate. Exemplary transesterification catalysts can further include a combination of a phase transfer catalyst of formula (R³)₄Q⁺X above, wherein each R³ is the same or different, and is a C₁₋₁₀ alkyl group; Q is a nitrogen or phosphorus atom; and X is a halogen atom or a C₁₋₈ alkoxy group or C₆₋₁₈ aryloxy group. Exemplary phase transfer catalyst salts include, for example, [CH₃(CH₂)₃]₄NX, [CH₃(CH₂)₃]₄PX, [CH₃(CH₂)₅]₄NX, [CH₃(CH₂)₆]₄NX, [CH₃(CH₂)₄]₄NX, CH₃[CH₃(CH₂)₃]₃NX, and CH₃[CH₃(CH₂)₂]₃NX, wherein X is Cl⁻, Br⁻, a C₁₋₈ alkoxy group or a C₆₋₁₈ aryloxy group. Examples of such transesterification catalysts include tetrabutylammonium hydroxide, methyltributylammonium hydroxide, tetrabutylammonium acetate, tetrabutylphosphonium hydroxide, tetrabutylphosphonium acetate, tetrabutylphosphonium phenolate, or a combination comprising at least one of the foregoing. Other melt transesterification catalysts include alkaline earth metal salts or alkali metal salts. In various aspects, where a beta catalyst is desired, the beta catalyst can be present in a molar ratio, relative to the alpha catalyst, of less than or equal to 10, specifically less than or equal to 5, more specifically less than or equal to 1, and still more specifically less than or equal to 0.5. In other aspects, the melt polymerization reaction disclosed herein uses only an alpha catalyst as described hereinabove, and is substantially free of any beta catalyst. As defined herein, “substantially free of” can mean where the beta catalyst has been excluded from the melt polymerization reaction. In one aspect, the beta catalyst is present in an amount of less than about 10 ppm, specifically less than 1 ppm, more specifically less than about 0.1 ppm, more specifically less than or equal to about 0.01 ppm, and more specifically less than or equal to about 0.001 ppm, based on the total weight of all components used in the melt polymerization reaction.

In one aspect, a melt process employing an activated carbonate is utilized. As used herein, the term “activated carbonate”, is defined as a diarylcarbonate that is more reactive than diphenylcarbonate in transesterification reactions. Specific non-limiting examples of activated carbonates include bis(o-methoxycarbonylphenyl)carbonate, bis(o-chlorophenyl)carbonate, bis(o-nitrophenyl)carbonate, bis(o-acetylphenyl)carbonate, bis(o-phenylketonephenyl)carbonate, bis(o-formylphenyl)carbonate.

Examples of specific ester-substituted diarylcarbonates include, but are not limited to, bis(methylsalicyl)carbonate (CAS Registry No. 82091-12-1) (also known as BMSC or bis(o-methoxycarbonylphenyl)carbonate), bis(ethylsalicyl)carbonate, bis(propylsalicyl)carbonate, bis(butylsalicyl)carbonate, bis(benzylsalicyl)carbonate, bis(methyl-4-chlorosalicyl)carbonate and the like. In one aspect, bis(methylsalicyl)carbonate is used as the activated carbonate in melt polycarbonate synthesis due to its lower molecular weight and higher vapor pressure.

Some non-limiting examples of non-activating groups which, when present in an ortho position, would not be expected to result in activated carbonates are alkyl, cycloalkyl or cyano groups. Some specific and non-limiting examples of non-activated carbonates are bis(o-methylphenyl)carbonate, bis(p-cumylphenyl)carbonate, bis(p-(1,1,3,3-tetramethyl)butylphenyl)carbonate and bis(o-cyanophenyl)carbonate. Unsymmetrical combinations of these structures can also be used as non-activated carbonates.

In one aspect, an end-capping agent (also referred to as a chain-stopper) can optionally be used to limit molecular weight growth rate, and so control molecular weight in the polycarbonate. Exemplary chain-stoppers include certain monophenolic compounds (i.e., phenyl compounds having a single free hydroxy group), monocarboxylic acid chlorides, and/or monochloroformates. Phenolic chain-stoppers are exemplified by phenol and C₁-C₂₂ alkyl-substituted phenols such as p-cumyl-phenol, resorcinol monobenzoate, and p- and tertiary-butyl phenol, cresol, and monoethers of diphenols, such as p-methoxyphenol. Alkyl-substituted phenols with branched chain alkyl substituents having 8 to 9 carbon atoms can be specifically mentioned. Certain monophenolic UV absorbers can also be used as a capping agent, for example 4-substituted-2-hydroxybenzophenones and their derivatives, aryl salicylates, monoesters of diphenols such as resorcinol monobenzoate, 2-(2-hydroxyaryl)-benzotriazoles and their derivatives, 2-(2-hydroxyaryl)-1,3,5-triazines and their derivatives, and the like.

In another aspect, endgroups can be derived from the carbonyl source (i.e., the diaryl carbonate), from selection of monomer ratios, incomplete polymerization, chain scission, and the like, as well as any added end-capping groups, and can include derivatizable functional groups such as hydroxy groups, carboxylic acid groups, or the like. In one aspect, the endgroup of a polycarbonate, including an isosorbide-based polycarbonate polymer as defined herein, can comprise a structural unit derived from a diaryl carbonate, where the structural unit can be an endgroup. In a further aspect, the endgroup is derived from an activated carbonate. Such endgroups can be derived from the transesterification reaction of the alkyl ester of an appropriately substituted activated carbonate, with a hydroxy group at the end of a polycarbonate polymer chain, under conditions in which the hydroxy group reacts with the ester carbonyl from the activated carbonate, instead of with the carbonate carbonyl of the activated carbonate. In this way, structural units derived from ester containing compounds or substructures derived from the activated carbonate and present in the melt polymerization reaction can form ester endgroups. In an aspect, the ester endgroup derived from a salicylic ester can be a residue of BMSC or other substituted or unsubstituted bis(alkyl salicyl)carbonate such as bis(ethyl salicyl)carbonate, bis(propyl salicyl)carbonate, bis(phenyl salicyl)carbonate, bis(benzyl salicyl)carbonate, or the like.

In one aspect, where a combination of alpha and beta catalysts are used in the melt polymerization, an isosorbide-based polycarbonate polymer prepared from an activated carbonate can comprise endgroups in an amount of less than 2,000 ppm, less than 1,500 ppm, or less than 1,000 ppm, based on the weight of the polycarbonate. In another aspect, where only an alpha catalyst is used in the melt polymerization, an isosorbide-based polycarbonate polymer prepared from an activated carbonate can comprise endgroups in an amount of less than or equal to 500 ppm, less than or equal to 400 ppm, less than or equal to 300 ppm, or less than or equal to 200 ppm, based on the weight of the polycarbonate.

In one aspect, the reactants for the polymerization reaction using an activated aromatic carbonate can be charged into a reactor either in the solid form or in the molten form. Initial charging of reactants into a reactor and subsequent mixing of these materials under reactive conditions for polymerization can be conducted in an inert gas atmosphere such as a nitrogen atmosphere. The charging of one or more reactants can also be done at a later stage of the polymerization reaction. Mixing of the reaction mixture is accomplished by any methods known in the art, such as by stirring. Reactive conditions include time, temperature, pressure and other factors that affect polymerization of the reactants. Typically the activated aromatic carbonate is added at a mole ratio of 0.8 to 1.3, and more preferably 0.9 to 1.3, and all subranges there between, relative to the total moles of monomer unit compounds (i.e., isosorbide, aromatic dihydroxy compound, and aliphatic diacid or diol). In a specific aspect, the molar ratio of activated aromatic carbonate to monomer unit compounds is 1.013 to 1.29, specifically 1.015 to 1.028. In another specific aspect, the activated aromatic carbonate is BMSC.

In one aspect, the melt polymerization reaction can be conducted by subjecting the reaction mixture to a series of temperature-pressure-time protocols. In some aspects, this involves gradually raising the reaction temperature in stages while gradually lowering the pressure in stages. In one aspect, the pressure is reduced from about atmospheric pressure at the start of the reaction to about 1 millibar (100 Pa) or lower, or in another aspect to 0.1 millibar (10 Pa) or lower in several steps as the reaction approaches completion. The temperature can be varied in a stepwise fashion beginning at a temperature of about the melting temperature of the reaction mixture and subsequently increased to final temperature. In one aspect, the reaction mixture is heated from room temperature to about 150° C. In such an aspect, the polymerization reaction starts at a temperature of about 150° C. to about 220° C. In another aspect, the polymerization temperature can be up to about 220° C. In other aspects, the polymerization reaction can then be increased to about 250° C. and then optionally further increased to a temperature of about 320° C., and all subranges there between. In one aspect, the total reaction time can be from about 30 minutes to about 200 minutes and all subranges there between. This procedure will generally ensure that the reactants react to give polycarbonates with the desired molecular weight, glass transition temperature and physical properties. The reaction proceeds to build the polycarbonate chain with production of ester-substituted alcohol by-product such as methyl salicylate. In one aspect, efficient removal of the by-product can be achieved by different techniques such as reducing the pressure. Generally the pressure starts relatively high in the beginning of the reaction and is lowered progressively throughout the reaction and temperature is raised throughout the reaction.

In one aspect, the progress of the reaction can be monitored by measuring the melt viscosity or the weight average molecular weight of the reaction mixture using techniques known in the art such as gel permeation chromatography. These properties can be measured by taking discrete samples or can be measured on-line. After the desired melt viscosity and/or molecular weight is reached, the final polycarbonate product can be isolated from the reactor in a solid or molten form. It will be appreciated by a person skilled in the art, that the method of making aliphatic homopolycarbonate and aliphatic-aromatic copolycarbonates as described in the preceding sections can be made in a batch or a continuous process and the process disclosed herein is preferably carried out in a solvent free mode. Reactors chosen should ideally be self-cleaning and should minimize any “hot spots.” However, vented extruders similar to those that are commercially available can be used.

In one aspect, the aliphatic homopolycarbonate and aliphatic-aromatic copolycarbonate can be prepared in an extruder in presence of one or more catalysts, wherein the carbonating agent is an activated aromatic carbonate. In one aspect, the reactants for the polymerization reaction can be fed to the extruder in powder or molten form. In another aspect, the reactants are dry blended prior to addition to the extruder. The extruder can be equipped with pressure reducing devices (e.g., vents), which serve to remove the activated phenol by-product and thus drive the polymerization reaction toward completion. The molecular weight of the polycarbonate product can, in various aspects, be manipulated by controlling, among other factors, the feed rate of the reactants, the type of extruder, the extruder screw design and configuration, the residence time in the extruder, the reaction temperature and the pressure reducing techniques present on the extruder. The molecular weight of the polycarbonate product can also depend upon the structures of the reactants, such as, activated aromatic carbonate, aliphatic diol, dihydroxy aromatic compound, and the catalyst employed. Many different screw designs and extruder configurations are commercially available that use single screws, double screws, vents, back flight and forward flight zones, seals, and sidestreams. One skilled in the art can find the best designs using generally known principals of commercial extruder design. Controlling the ratio of diarylcarbonate/diol, specifically BMSC/diol can impact the Mw when using an activated carbonate. A lower ratio can generally provide a higher molecular weight.

In one aspect, decomposition by-products of the reaction that are of low molecular weight can be removed by, for example, devolatilization during reaction and/or extrusion to reduce the amount of such volatile compounds. The volatiles typically removed can include unreacted starting diol materials, carbonate precursor materials, but are more specifically the decomposition products of the melt-polymerization reaction.

In one aspect, polymers with high isosorbide content can be difficult to process because of the high T_(g) that accompanies homogeneous blocks of isosorbide carbonate units. Therefore compositions with isosorbide are expected to possess a somewhat higher T_(g) compared to similar compositions based on BPA. Such runs of isosorbide carbonate units can traditionally require high processing temperatures of greater than or equal to 280° C., which can lead to degradation of the isosorbide carbonate units and thus the polycarbonate overall. In addition, isosorbide homopolymers, or isosorbide-based polycarbonates with high isosorbide carbonate unit content (translating to isosorbide block lengths of greater than about 20 isosorbide units) and prepared by interfacial polymerization methods can crystallize, making them more difficult to process than either isosorbide copolymers or non-isosorbide containing polycarbonates such as, for example, bisphenol A homopolycarbonate.

In addition to the isosorbide-based polycarbonates described above, thermoplastic compositions comprising combinations of the isosorbide-based polycarbonate with other thermoplastic polymers that do not comprise isosorbide-based carbonate units can be prepared using, for example other polycarbonates including homopolycarbonates and other polycarbonate copolymers (i.e., copolycarbonates). These combinations can comprise 1 to 99 wt %, specifically 10 to 90, more specifically 20 to 80 wt % of the isosorbide-based polycarbonate, with the remainder of the compositions being other of the foregoing additional polymers, and/or additives as described below. In an aspect, the thermoplastic composition comprises the isosorbide-based polycarbonate, an additional polymer, and/or an additive.

In addition to the isosorbide-based polycarbonate, the thermoplastic composition can include various additives ordinarily incorporated in resin compositions of this type, with the proviso that the additives are selected so as to not significantly adversely affect the desired properties of the thermoplastic composition. Combinations of additives can be used. Such additives can be mixed at a suitable time during the mixing of the components for forming the composition.

In other aspects, a polycarbonate composition can comprise one or more of an antioxidant, flame retardant, heat stabilizer, light stabilizer, UV absorbing additive, plasticizer, lubricant, mold release agent, antistatic agent, colorant (e.g., pigment and/or dye), or a combination thereof.

Thermoplastic compositions comprising the isosorbide-based polycarbonate can be manufactured by various methods. For example, powdered isosorbide-based polycarbonate, other polymer (if present), and/or other optional components are first blended, optionally with fillers in a HENSCHEL-Mixer® high speed mixer. Other low shear processes, including but not limited to hand mixing, can also accomplish this blending. The blend is then fed into the throat of a twin-screw extruder via a hopper. Alternatively, at least one of the components can be incorporated into the composition by feeding directly into the extruder at the throat and/or downstream through a sidestuffer. Additives can also be compounded into a masterbatch with a desired polymeric resin and fed into the extruder. The extruder is generally operated at a temperature higher than that necessary to cause the composition to flow. The extrudate is immediately quenched in a water batch and pelletized. The pellets, so prepared, when cutting the extrudate can be one-fourth inch long or less as desired. Such pellets can be used for subsequent molding, shaping, or forming.

The process disclosed herein can be used to prepare aliphatic polycarbonate and aliphatic-aromatic copolycarbonates having a weight average molecular weight (Mw) of greater than about 39,000 g/mol. The glass transition temperature (Tg) of the isosorbide-based polycarbonates can be less than or equal to about 135° C. The number average molecular weights (Mn) of the aliphatic-aromatic copolycarbonate is greater than about 17,000 g/mol. The homo and copolycarbonates disclosed herein can further exhibit lower Refractive Index (RI), transparency (high % transmission and low haze), higher scratch resistance and lower oxygen permeability compared to conventional BPA homopolycarbonate. Furthermore, the disclosed homo and copolycarbonates are also optically active where prepared using enantiomerically pure or enantiomerically enriched aliphatic diol (e.g., D-(+)-isosorbide, and the like).

In various aspects, the homo and copolycarbonates can be used in making various articles including, but not limited to a film, a sheet, an optical wave guide, a display device and a light emitting diode prism. Furthermore the polycarbonates can be used in making articles such as, exterior body panels and parts for outdoor vehicles and devices including automobiles, protected graphics such as signs, outdoor enclosures such as telecommunication and electrical connection boxes, and construction applications such as roof sections, wall panels and glazing. Multilayer articles made of the disclosed polycarbonates particularly include articles which will be exposed to UV-light, whether natural or artificial, during their lifetimes, and most particularly outdoor articles; i.e., those intended for outdoor use. Suitable articles are exemplified by automotive, truck, military vehicle, and motorcycle exterior and interior components, including panels, quarter panels, rocker panels, trim, fenders, doors, decklids, trunklids, hoods, bonnets, roofs, bumpers, fascia, grilles, minor housings, pillar appliques, cladding, body side moldings, wheel covers, hubcaps, door handles, spoilers, window frames, headlamp bezels, headlamps, tail lamps, tail lamp housings, tail lamp bezels, license plate enclosures, roof racks, and running boards; enclosures, housings, panels, and parts for outdoor vehicles and devices; enclosures for electrical and telecommunication devices; outdoor furniture; aircraft components; boats and marine equipment, including trim, enclosures, and housings; outboard motor housings; depth finder housings, personal water-craft; jet-skis; pools; spas; hot-tubs; steps; step coverings; building and construction applications such as glazing, roofs, windows, floors, decorative window furnishings or treatments; treated glass covers for pictures, paintings, posters, and like display items; wall panels, and doors; protected graphics; outdoor and indoor signs; enclosures, housings, panels, and parts for automatic teller machines (ATM); enclosures, housings, panels, and parts for lawn and garden tractors, lawn mowers, and tools, including lawn and garden tools; window and door trim; sports equipment and toys; enclosures, housings, panels, and parts for snowmobiles; recreational vehicle panels and components; playground equipment; articles made from plastic-wood combinations; golf course markers; utility pit covers; computer housings; desk-top computer housings; portable computer housings; lap-top computer housings; palm-held computer housings; monitor housings; printer housings; keyboards; facsimile machine housings; copier housings; telephone housings; mobile phone housings; radio sender housings; radio receiver housings; light fixtures; lighting appliances; network interface device housings; transformer housings; air conditioner housings; cladding or seating for public transportation; cladding or seating for trains, subways, or buses; meter housings; antenna housings; cladding for satellite dishes; coated helmets and personal protective equipment; coated synthetic or natural textiles; coated photographic film and photographic prints; coated painted articles; coated dyed articles; coated fluorescent articles; coated foam articles; and like applications.

Polycarbonate Blends

In another aspect, the polycarbonate material of the present invention can comprise a blend of polycarbonate and at least one other polymeric material. In one aspect, the polycarbonate itself can comprise a mixture or blend of polycarbonate materials (e.g., a mixture of bio-sourced polycarbonate and bisphenol A sourced polycarbonate). In another aspect, the one or more other polymeric materials mixed and/or blended with a polycarbonate can comprise a polymer system capable of maintaining and/or improving the heat deflection temperature of the resulting material. In various aspects, a polycarbonate can be mixed and/or blended with polyphenylene ether (PPO), BPAPC-PPPBP, BPADP, 3-phenylsulfonylbenezenesulfonic acid potassium salt (KSS), Rimer salts, polytetrafluoroethylene encapsulated poly(styrene-co-acrylonitrile), a SEBS block copolymer, PTFE, or a combination thereof. In still other aspects, the polycarbonate material, such as, for example, Iso ter PC, can be mixed and/or blended with other polymers, such as, for example, high heat polymers, not specifically recited herein. One of skill in the art, in possession of this disclosure, could readily select an appropriate polycarbonate and/or polycarbonate blend material.

Impact Modifier

The polycarbonate of the present invention comprises one or more impact modifiying agents, or impact modifiers. In one aspect, suitable impact modifiers are can be high molecular weight elastomeric materials derived from olefins, monovinyl aromatic monomers, acrylic and methacrylic acids and their ester derivatives, as well as conjugated dienes. The polymers formed from conjugated dienes can be fully or partially hydrogenated. The elastomeric materials can be in the form of homopolymers or copolymers, including random, block, radial block, graft, and core-shell copolymers. In another aspect, a combination of any two or more individual impact modifiers can be used.

An exemplary type of impact modifier is an elastomer-modified graft copolymer comprising an elastomeric (i.e., rubbery) polymer substrate having a T_(g) less than about 10° C., less than about −10° C., or about −40° C. to −80° C., and a rigid polymeric superstrate grafted to the elastomeric polymer substrate. Materials suitable for use as the elastomeric phase include, for example, conjugated diene rubbers, for example polybutadiene and polyisoprene; copolymers of a conjugated diene with less than about 50 wt % of a copolymerizable monomer, for example a monovinylic compound such as styrene, acrylonitrile, n-butyl acrylate, or ethyl acrylate; olefin rubbers such as ethylene propylene copolymers (EPR) or ethylene-propylene-diene monomer rubbers (EPDM); ethylene-vinyl acetate rubbers; silicone rubbers; elastomeric C₁₋₈ alkyl(meth)acrylates; elastomeric copolymers of C₁₋₈ alkyl(meth)acrylates with butadiene and/or styrene; or combinations comprising at least one of the foregoing elastomers. Materials suitable for use as the rigid phase include, for example, monovinyl aromatic monomers such as styrene and alpha-methyl styrene, and monovinylic monomers such as acrylonitrile, acrylic acid, methacrylic acid, and the C₁₋₆ esters of acrylic acid and methacrylic acid, specifically methyl methacrylate.

Exemplary elastomer-modified graft copolymers include those formed from styrene-butadiene-styrene (SBS), styrene-butadiene rubber (SBR), styrene-ethylene-butadiene-styrene (SEBS), ABS (acrylonitrile-butadiene-styrene), acrylonitrile-ethylene-propylene-diene-styrene (AES), styrene-isoprene-styrene (SIS), methyl methacrylate-butadiene-styrene (MBS), and styrene-acrylonitrile (SAN).

In one aspect, the inventive polycarbonate composition comprises a styrene-ethylene-butadiene-styrene (SEBS) elastomer. In one aspect, the amount of styrene in a SEBS material can vary. In various aspects, the amount of styrene in a SEBS impact modifier can range from about 5 wt. % to about 95 wt. %, for example, about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 wt. %, including all subranges therein. In one aspect, a SEBS impact modifier comprises about 13 wt. % styrene, such as, for example, KRATON® G 1657M, available from Kraton Polymers. In another aspect, a SEBS impact modifier comprises about 33 wt. % styrene, such as, for example, KRATON® G 1651H, available from Kraton Polymers. In yet another aspect, a SEBS impact modifier comprises about 67 wt. % styrene, such as, for example, TUFTEC® H1043, available from Asahi Kasei Chemicals Corporation. In a preferred aspect, a SEBS impact modifier comprises from about 20 wt. % to about 45 wt. %, for example, about 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, or 45 wt. % styrene. In other aspects, other SEBS impact modifiers comprising various amounts of styrene can be used. Such impact modifiers are commercially available, and one of skill in the art, in possession of this disclosure, could readily select an appropriate SEBS impact modifier.

In one aspect, an inventive polycarbonate composition can comprise from about 1 wt. % to 30 wt %, for example, about 1, 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, or 30 wt. %, of an impact modifier, based on the total weight of the isosorbide-based polycarbonate, and any additional polymer including impact modifier, in the composition. In another aspect, an inventive polycarbonate composition can comprise from about 1 wt. % to about 15 wt. %, for example, about 1, 3, 5, 7, 9, 11, 13, or 15 wt. %, or from about 1 wt. % to about 10 wt. %, for example, about 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 wt. % of a SEBS impact modifier. In another aspect, an inventive polycarbonate composition can comprise from about 1 wt. % to about 6 wt. %, for example, about 1, 1.25, 1.5, 1.75, 2, 2.25, 2.5, 2.75, 3, 3.25, 3.5, 3.75, 4, 4.25, 4.5, 4.75, 5, 5.25, 5.5, 5.75, or 6 wt. % of an impact modifier. In a specific aspect, an inventive polycarbonate composition comprises from about 1 wt. % to about 6 wt. %, of SEBS having about 33% styrene content. In another aspect, an inventive polycarbonate composition comprises from about 1 wt. % to about 6 wt. % of SEBS having about 66% styrene content. In one aspect, a polycarbonate composition comprises approximately 6 wt. % of a SEBS impact modifier. In other aspects, the a specific amount of any one or more impact modifiers can vary, based on the remaining components in the system and desired properties of the resulting polymer. One of skill in the art, in possession of this disclosure, could readily select an appropriate amount of any one or more impact modifiers to use in a polymer composition.

In one aspect, a polycarbonate without an additional impact modifier can have a low Notched Izod Impact (NII) rating, for example, less than about 5. In one aspect, when a SEBS impact modifier is blended with a bio-sourced polycarbonate, the NII strength can be improved as compared to conventional bio-sourced polycarbonates not containing a SEBS impact modifier. In one aspect, a bio-sourced polycarbonate blended with a SEBS impact modifier comprising about 13 wt. % styrene can have an NII of at least about 5, at least about 6, or at least about 7 kJ/m². In another aspect, a bio-sourced polycarbonate blended with a SEBS impact modifier comprising about 13 wt. % styrene can have an NII of about 7.6 kJ/m². In another aspect, a bio-sourced polycarbonate blended with a SEBS impact modifier comprising about 67 wt. % styrene can have an NII of at least about 5, at least about 6, or at least about 7 kJ/m². In yet another aspect, a bio-sourced polycarbonate blended with a SEBS impact modifier comprising about 33 wt. % styrene can have an NII of at least about 5, at least about 10, at least about 15, or at least about 20 kJ/m², for example, about 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, or 25 kJ/m².

In another aspect, the improvement in NII strength of a bio-sourced polycarbonate upon addition of a SEBS impact modifier can be at least about 2 fold, at least about 3 fold, at least about 4 fold, or at least about 5 fold.

In another aspect, a bio-sourced polycarbonate can retain a desirable MVR value upon addition of a SEBS impact modifier. In another aspect, a bio-sourced polycarbonate can retain a desirable tensile modulus and/or tensile strength upon addition of a SEBS impact modifier. In yet another aspect, a bio-sourced polycarbonate can exhibit no more than a marginal reduction in tensile modulus and/or tensile strength upon addition of a SEBS impact modifier (for example, retaining at least about 75%, 80%, 85%, 90%, or 95% of the value prior to addition of the impact modifier).

When subjected to tensile fracture tests, an Iso65 ter PC sample blended with a SEBS impact modifiers comprising 33 wt. % styrene showed no delamination. The lack of delamination of such a blend under tensile fracture suggests a good compatibility between the Iso65 ter PC and SEBS components.

While not wishing to be bound by theory, the transparency of an Iso ter PC/SEBS blend generally increases with increasing SEBS content. For example, an Iso65 ter PC resin blended without a SEBS impact modifier can have a transparency of about 84.5%. Upon addition of a SEBS impact modifier comprising about 33 wt. % styrene, the transparency can be about 66%. Upon addition of a SEBS impact modifier comprising about 67 wt. % styrene, the transparency can be about 82.5%, or about 97.6% of the transparency of the native resin. Similarly, an Iso80 ter PC resin having a higher content of bio-sourced material, can have a transparency of about 87.9%. Upon addition of a SEBS impact modifier comprising about 33 wt. % styrene, the transparency of the Iso80 ter PC/SEBS blend can be about 83.6%, or about 95% of the transparency of the native resin.

In various aspect, addition of a SEBS impact modifier to a conventional bis-phenol A polycarbonate (BPAPC) does not result in any or any significant improvement in NII strength.

Other Additives

In other aspects, the inventive polycarbonate can comprise one or more other materials that can maintain and/or improve various properties of the resulting material. In various aspects, the inventive polycarbonate can comprise an epoxy, an anti-drip agent, filler, or a combination thereof.

In one aspect, the inventive polycarbonate composition comprises an epoxy, such as, for example, a dime acid diglycidyl ester epoxy (DADGE®, available from Aldrich), a 3,4-epoxy cyclohexyl methyl-3,4-epoxy cyclohexane carboxylate (ERL-4221, available from Aldrich), a modified styrene acrylic polymer (ADR-4368F, available from Aldrich), or a combination thereof. In other aspects, the inventive polycarbonate composition can comprise an epoxy material not specifically recited herein, provided that such an epoxy material is chemically compatible with the remaining components of the composition and that the epoxy material does not adversely affect the desired properties of the composition. In one aspect, the inventive polycarbonate comprises DADGE. In another aspect, the inventive polycarbonate comprises ERL-4221. In yet another aspect, the inventive polycarbonate comprises ADR-4368F. In another aspect, the inventive polycarbonate does not comprise an epoxy. An epoxy material, if present, can be present at any concentration that can maintain or improve the properties of the resulting material. In various aspects, an epoxy material can be present in an amount of from about 0.1 wt. % to about 5 wt. %, for example, about 0.1, 0.3, 0.5, 0.7, 0.9, 1, 2, 1.4, 1.6, 1.8, 2, 2.5, 3, 3.5, 4, 4.5, or 5 wt. %; or from about 0.5 wt. % to about 1.0 wt. %, for example, about 0.5, 0.6, 0.7, 0.8, 0.9, or 1 wt. %. In other aspects, an epoxy material can be present in an amount less than about 0.1 wt. % or greater than about 5 wt. %, and the present invention is not intended to be limited to any particular epoxy concentration. In one aspect, a polycarbonate material comprises about 2% of a styrenic epoxy material, such as, for example, ADR-4368F. In another aspect, a polycarbonate material comprises about 3 wt. % of a styrenic epoxy material, such as, for example, ADR-4368F.

In one aspect, the presence of an epoxy material, such as, for example, a styrenic epoxy, can provide minimize and/or eliminate delamination under tensile fracture. In a specific aspect, the addition of about 3 wt. % of a styrenic epoxy to an Iso ter PC, such as, for example, an Iso65 ter PC, can prevent delamination of the resulting material.

In another aspect, the addition of an epoxy, such as, for example, a styrenic epoxy, to an Iso ter PC resin does not adversely affect the transparency and/or NII strength of the material.

In another aspect, the inventive polycarbonate composition can comprise a filler, such as, for example, an inorganic filler. The specific composition of a filler, if present, can vary, provided that the filler is chemically compatible with the remaining components of the polycarbonate composition. In one aspect, the polycarbonate composition comprises a filler, such as, for example, talc. If present, the amount of filler can comprise any amount suitable for a polycarbonate composition that does not adversely affect the desired properties thereof. In one aspect, the inventive polycarbonate comprises about 1 wt. % to about 10 wt. % of a filler.

In another aspect, a filler can comprise silicates and silica powders such as aluminum silicate (mullite), synthetic calcium silicate, zirconium silicate, fused silica, crystalline silica graphite, natural silica sand, or the like; boron powders such as boron-nitride powder, boron-silicate powders, or the like; oxides such as TiO₂, aluminum oxide, magnesium oxide, or the like; calcium sulfate (as its anhydride, dihydrate or trihydrate); calcium carbonates such as chalk, limestone, marble, synthetic precipitated calcium carbonates, or the like; talc, including fibrous, modular, needle shaped, lamellar talc, or the like; wollastonite; surface-treated wollastonite; glass spheres such as hollow and solid glass spheres, silicate spheres, cenospheres, aluminosilicate (atmospheres), or the like; kaolin, including hard kaolin, soft kaolin, calcined kaolin, kaolin comprising various coatings known in the art to facilitate compatibility with the polymeric matrix resin, or the like; single crystal fibers or “whiskers” such as silicon carbide, alumina, boron carbide, iron, nickel, copper, or the like; fibers (including continuous and chopped fibers) such as asbestos, carbon fibers, glass fibers, such as E, A, C, ECR, R, S, D, or NE glasses, or the like; sulfides such as molybdenum sulfide, zinc sulfide or the like; barium compounds such as barium titanate, barium ferrite, barium sulfate, heavy spar, or the like; metals and metal oxides such as particulate or fibrous aluminum, bronze, zinc, copper and nickel or the like; flaked fillers such as glass flakes, flaked silicon carbide, aluminum diboride, aluminum flakes, steel flakes or the like; fibrous fillers, for example short inorganic fibers such as those derived from blends comprising at least one of aluminum silicates, aluminum oxides, magnesium oxides, and calcium sulfate hemihydrate or the like; natural fillers and reinforcements, such as wood flour obtained by pulverizing wood, fibrous products such as cellulose, cotton, sisal, jute, starch, cork flour, lignin, ground nut shells, corn, rice grain husks or the like; organic fillers such as polytetrafluoroethylene; reinforcing organic fibrous fillers formed from organic polymers capable of forming fibers such as poly(ether ketone), polyimide, polybenzoxazole, poly(phenylene sulfide), polyesters, polyethylene, aromatic polyamides, aromatic polyimides, polyetherimides, polytetrafluoroethylene, acrylic resins, poly(vinyl alcohol) or the like; as well as additional fillers and reinforcing agents such as mica, clay, feldspar, flue dust, fillite, quartz, quartzite, perlite, tripoli, diatomaceous earth, carbon black, or the like, or combinations comprising at least one of the foregoing fillers or reinforcing agents.

In one aspect, a filler, if present, can be coated with a layer of metallic material to facilitate conductivity, or surface treated with silanes to improve adhesion and dispersion with the polymeric matrix resin. In addition, the reinforcing fillers can be provided in the form of monofilament or multifilament fibers and can be used individually or in combination with other types of fiber, through, for example, co-weaving or core/sheath, side-by-side, orange-type or matrix and fibril constructions, or by other methods known to one skilled in the art of fiber manufacture. Exemplary co-woven structures include, for example, glass fiber-carbon fiber, carbon fiber-aromatic polyimide (aramid) fiber, and aromatic polyimide fiberglass fiber or the like. Fibrous fillers can be supplied in the form of, for example, rovings, woven fibrous reinforcements, such as 0-90 degree fabrics or the like; non-woven fibrous reinforcements such as continuous strand mat, chopped strand mat, tissues, papers and felts or the like; or three-dimensional reinforcements such as braids.

Properties of Improved Bio-Sourced Polycarbonate

In various aspects, the inventive bio-sourced polycarbonate compositions of the present disclosure can provide improved properties as compared to conventional bio-sourced polycarbonate materials. In one aspect, the inventive polycarbonate composition exhibit improved resistance to aging, for example, heat and hydro aging and UV aging.

In one aspect, samples of inventive polycarbonate compositions comprising an impact modifier, such as, for example, a SEBS impact modifier, can be subjected to heat and hydro aging test by conditioning samples at, for example, 85° C. (85% relative humidity) for about 48 hours. Similarly, UV aging can be performed according to, for example, ASTM G 154-00ae1 protocols. The extent of aging in a bio-sourced polycarbonate resin can be determined by monitoring the color shift in a samples

In one aspect, an Iso ter PC comprising a SEBS impact modifier can exhibit a color shift of less than about 1, for example, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, or less, or less than about 0.5, for example, 0.5, 0.4, 0.3, 0.2, or less, when subjected to heat and hydro aging. In another aspect, an Iso ter PC comprising a SEBS impact modifier can exhibit a color shift of less than about 1, for example, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, or less, or less than about 0.5, for example, 0.5, 0.4, 0.3, 0.2, or less, when subjected to UV aging.

In contrast, an Iso65 ter PC sample blended with an MBS impact modifier exhibits color shifts of about 23 and 5 when subjected to heat/hydro aging and UV aging, respectively. Thus, in one aspect, the addition of a SEBS impact modifier can improve and/or substantially improve resistance to aging of an Iso ter PC as compared to an Iso ter PC resin alone or with other impact modifiers, such as, for example, MBS.

In another aspect, the inventive polycarbonate comprising a SEBS impact modifier can exhibit good scratch resistance, similar or greater than that of an Iso ter PC resin without an impact modifier. In another aspect, the addition of a SEBS impact modifier does not adversely affect the scratch resistance of a bio-sourced polycarbonate.

In other aspects, a bio-source polycarbonate comprising a SEBS impact modifier can exhibit good transparency, good retention of heat deflection temperature, and no delamination under tensile fracture. In another aspect, polycarbonate materials having high bio-content (e.g., over 50%, 60%, or 70%) and comprising a SEBS impact modifier, as described herein, ca provide ductility, aging resistance, and transparency

In various aspects, HDR measurements were determined using a 4 mm thick (+10%) bar per ISO 75/Ae at 1.8 MPa; MVR results were determined at 260° C. using a 2.16 kilogram load per ASTM D1238, and NII measurements were determined on one-eighth inch (3.18 mm) bars per ASTM D256 at room temperature (23° C.).

While typical aspects have been set forth for the purpose of illustration, the foregoing descriptions should not be deemed to be a limitation on the scope of the invention. Accordingly, various modifications, adaptations, and alternatives can occur to one skilled in the art without departing from the spirit and scope of the present invention.

EXAMPLES

The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the compounds, compositions, articles, devices and/or methods claimed herein are made and evaluated, and are intended to be purely exemplary of the invention and are not intended to limit the scope of what the inventors regard as their invention. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.), but some errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by weight, temperature is in ° C. or is at ambient temperature, and pressure is at or near atmospheric.

1. Iso Ter PC/SEBS Blends

In a first example, blends of Iso65 ter PC and three grades of SEBS were prepared and evaluated. The specific composition of each blend, together with the results are detailed in Table 2, below.

TABLE 2 Mechanical and Optical Properties of Iso-ter-PC/SEBS Blends Formulation CTG65 CS1 93/6 CS2 93/6 CS3 93/6 Iso65 ter PC 100 94 94 94 KRATON ® G 1657M 6 (13% PS) KRATON ® G 1651H 6 (33% PS) TUFTEC ® H1043 6 (67% PS) Total 100 100 100 100 Bio Content (by wt. %) 59.4 55.9 55.9 55.9 Tensile Modulus (MPa) 2762.6 2423.1 2486.5 2622.4 Elongation at Break (%) 15.0 9.7 17.8 12.9 Tensile Strength (MPa) 50.4 34.7 45.3 38.6 Delamination No Yes No Yes MVR (245° C. with 5 kg) 17.5 19.7 17.0 16.7 NII (kJ/m² at 23° C.) 3.00 7.64 20.16 6.41 Transparency (%) 84.5 38.5 66.1 82.5 Haze (%) 1.06 100 101 12.9 Yellowness Index (%) 31.9 17.92 33.36 18.3

The addition of SEBS (S1, S2, or S3) provided a measurable improvement to the notched izod impact strength of the Iso65 ter PC material. In particular, addition of S2 SEBS (33% styrene) resulted in a greater than five fold increase in NII strength as compared to the S1 and S3 SEBS grades.

MVR properties were maintained in each of the blends, but tensile modulus and strength exhibited a marginal reduction upon addition of the SEBS. It should be noted that the tensile fracture of blends S1 (13% styrene) and S3 (67% styrene) showed delamination, whereas the S2 blend (33% styrene) and the original Iso65 ter PC material did not delaminate. The lack of delamination for the S2 blend suggests good compatibility between the Iso65 ter PC and S2 SEBS materials.

The transparency of a blend increases with increasing styrene content in the SEBS. The transparency of the blend containing S3 SEBS is similar to that of the native Iso65 ter PC material.

For comparison, the refractive indices (RI) of individual components are detailed in Table 3, below. It should be noted that the refractive index of Iso65 ter PC and S3 are not well matched, yet the blend exhibited a high transparency (similar to the Iso65 ter PC).

TABLE 3 Refractive Index of Individual Components Materials Refractive Index S1 - KRATON ® G 1657M (13 1.498 S2 - KRATON ® G 1651H (33% 1.519 S3 - TUFTEC ® H1043 (67% PS) 1.555 Iso65 ter PC 1.536 Iso80 ter PC 1.520 Iso93 co PC 1.506 BPAPC (PC 105) 1.586

As a control experiment, comparative blends of BPAPC (PC 105) with the three grades of SEBS (S1, S2 & S3) were prepared and evaluated, the results of which are detailed in Table 4, below.

TABLE 4 Mechanical and Optical Properties of BPAPC/SEBS blends. Formulation PC105 PS1 PS2 PS3 BPAPC (PC 105) 100 94 94 94 KRATON ® G 1657M (13% PS) 6 KRATON ® G 1651H (33% PS) 6 TUFTEC ® H1043 (67% PS) 6 Total 100 100 100 100 Bio Content (by wt. %) 0 0 0 0 Tensile Modulus (MPa) 2280 2027 2037 2245 Elongation at Break (%) 81 42 99 88 Tensile Strength (MPa) 57 43 59 57 Delamination No Yes Yes Yes MVR (245° C. with 5 kg) 15.2 17.9 13.2 26.1 NII (kJ/m² at 23° C.) 65 54 55 62 Transparency (%) 91.6 25.5 36.2 58.9 Haze (%) 2.3 101.0 101.0 97.9 Yellowness Index (%) 2.4 −7.3 −7.3 −24.4

Unlike the blends of Iso65 ter PC and SEBS, no improvement in NII strength was observed upon addition of SEBS (S1, S2, or S3) to the BPAPC (PC 105) control polymer. FIG. 1 illustrates the normalized change in NII strength upon addition of each of the SEBS elastomers to the Iso65 ter PC and the BPAPC resins. In addition, each of the BPAPC/SEBS blends showed delamination under tensile fracture, indicating poor compatibility between the BPAPC and SEBS components. Also, the transparency of each of the BPAPC/SEBS blends dropped significantly as compared to the native BPAPC resin.

In summary, the addition of SEBS to BPAPC resin does not result in any improvement in NII strength, but does result in potential delamination and a loss of transparency. In comparison, addition of SEBS to Iso65 ter PC results in improved NII strength, good transparency, and no delamination (for Iso65 ter PC/S2 blend).

2. Addition of Styrenic Epoxy

In a second example, a styrenic epoxy was added to Iso65 ter PC/SEBS blends to improve tensile fracture properties and minimize or prevent delamination. The resulting samples were evaluated as detailed in Table 5, below.

TABLE 5 Effect of Styrenic Epoxy on Iso65 ter PC/SEBS Blends Formulation CS3 CS3A2 CS3A3 Iso65 ter PC 94 92 91 TUFTEC ® H1043 (67% PS) 6 6 6 ADR-4368 Styrenic Epoxy 2 3 Total 100 100 100 Bio Content (by wt. %) 55.9 54.7 54.1 Tensile Modulus (MPa) 2486.0 2528.0 2512.7 Elongation at Break (%) 12.80 11.59 10.36 Tensile Strength (MPa) 50.73 50.35 51.25 Delamination Yes Yes No MVR (250° C. with 5 kg) 24.159 11.396 9.263 NII (kJ/m² at 23° C.) 6.14 5.93 6.15 HDT 1.82 MPa Flatwise (° C.) 73.6 73.7 70.35 Transparency (%) 82.5 75.7 76.3 Haze (%) 12.9 29.3 32.1 Yellowness Index (%) 18.3 25.6 25.6

The retention of transparency and improvement in NII strength for an Iso65 ter PC/S3 (67% styrene) blend was described in Example 1. To improve tensile fracture properties, a styrenic epoxy (ADR-4368) was added in varying amounts. The addition of 3 wt. % styrenic epoxy resulted in no delamination under tensile fracture and good retention of transparency and NII strength.

3. Aging of Iso65 Ter PC/SEBS Blends

In a third example, the heat & hydro aging, and UV aging resistance of Iso65 ter PC/SEBS (S1, S2, and S3) blends were evaluated. Blends comprising Iso65 ter PC and one of S1, S2, or S3 SEBS were prepared and evaluated as detailed in Table 6, below. For heat & hydro aging tests, samples were conditioned for 48 hours at 85° C. with 85% relative humidity (RH). UV aging studies were conducted according to ASTM G 154-00ae1 test protocols. Samples comprising Iso65 ter PC alone and Iso65 ter PC/MBS were prepared and evaluated as control samples.

TABLE 6 Properties of Iso65 ter PC with Impact Modifiers Formulation CTG65 CM8S 93/6 CS2 93/6 CS3 93/6 Iso65 ter PC 100 94 94 94 MBS 6 S2 - KRATON ® G 6 1651H S3 - TUFTEC ® 6 H1043 Total 100 100 100 100 Bio Content 59.4 55.9 55.9 55.9 (by wt. %) NII (kJ/m² at 23° C.) 3.00 30.50 20.16 6.41 Heat & Hydro Aging Colorshift (ΔE) 0.86 23.37 0.47 0.48 UV Weatherability Aging Colorshift (ΔE) 1.83 5.25 0.31 0.90 Nano-Scratch Resistance Total Height of 1631.467 1959.486 1672.225 1522.279 Groove (nm) St. Dev. 28.627 38.068 80.971 16.639 Residual Scratch 1152.785 1415.37 1192.146 1074.276 Depth (nm) St. Dev. 14.904 20.57 95.908 16.62 Scratch Width (nm) 27.058 30.831 27.316 27.463 St. Dev 0.245 0.203 2.232 0.531

Aging resistance (heat & hydro aging and UV aging) was evaluated by monitoring the color change in the produced material (i.e., color shift). A lower amount of color shift indicates better aging resistance of the polymer. As illustrated in Table 6, the addition of MBS impact modifier to an Iso65 ter PC samples significantly improved NII strength, but also resulted in high color shift, indicating poor aging resistance as compared to the Iso65 ter PC control sample. In contrast, the addition of SEBS (S2 and S3) to Iso65 ter PC resulted in excellent aging resistance, as indicated by very small color shifts. The inventive Iso65 ter PC/SEBS (S2 and/or S3) blends also exhibited significantly improved (i.e., greater than five fold) in NII strength. FIG. 2 illustrates the color shift of the samples identified in Table 6.

In addition, the scratch resistance of Iso65 ter PC/SEBS blends was evaluated using a nano-scratch technique. As in aging studies, samples of Iso65 ter PC alone and Iso65 ter PC/MBS were prepared and evaluated as control samples. The total groove height, scratch depth and width were measured for each sample. For each of the Iso65 ter PC/SEBS blends, these values were similar to those obtained for the Iso65 ter PC control sample. In contrast, the Iso65 ter PC/MBS sample exhibited increases in groove height, depth, and width, indicating poor scratch resistance. In summary, the Iso65 ter PC/SEBS blend materials exhibit superior NII strength, together with good resistance to scratching, heat & hydro aging, and UV aging. FIG. 3 illustrates the groove height observed in scratch resistance measurements, as detailed in Table 6.

4. High Bio-Content Iso Ter PC

In a fourth example, samples of Iso ter PC containing higher amounts of bio-sourced isosorbide were evaluated. Specifically, samples of Iso80 ter PC were prepared wherein the bio-content of the Iso ter PC resin was greater than 73 wt. %. Blends were prepared from the Iso80 ter PC resin with S1, S2, and S3 SEBS materials. Evaluation results for the blends are detailed in Table 7, below.

TABLE 7 Mechanical and Optical Properties of Iso80 ter PC/SEBS Blends Formulation B0Z80 B80S1 B80S2 B80S3 Iso80 ter PC 100 94 94 94 S1 - KRATON ® G 1657M 6 S2 - KRATON ® G 1651H 6 S3 - TUFTEC ® H1043 6 Total 100 100 100 100 Bio Content (by wt. %) 73.1 68.7 68.7 68.7 Tensile Modulus (MPa) 2651.36 2342.08 2344.10 2575.92 Elongation at Break (%) 1.84 16.17 34.12 15.65 Tensile Strength (MPa) 47.35 46.80 45.48 48.59 Delamination No No No No MVR (250° C. with 5 kg) 28.2 20.8 10.0 12.4 NII (kJ/m² at 23° C.) 2.35 5.02 11.60 2.95 HDT 1.82 MPa (Flatwise° C.) 77.5 74.2 74.1 75.3 Transparency (%) 87.9 43.9 83.6 61.0 Haze (%) 6.1 101.0 9.0 91.3 Yellowness Index (%) 12.8 17.7 8.9 32.3

Among the grades of SEBS evaluated (S1, S2, and S3), the S2 SEBS blend exhibited good improvement in NII strength, together with good retention of transparency. In addition, the Iso80 ter PC/S2 blend exhibited good retention of heat deflection temperature (HDT) and mechanical properties. None of the Iso80 ter PC/SEBS blends showed any delamination under tensile fracture, indicated good compatibility between the blend components. In summary, the results illustrate the advantages of high bio-content Iso ter PC/SEBS blends for use particular applications.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. Other aspects of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims. 

What is claimed is:
 1. A polycarbonate composition prepared from a bio-sourced isosorbide, the polycarbonate composition comprising a styrene-ethylene-butylene-styrene polymer and a styrenic epoxy, wherein the styrene-ethylene-butylene-styrene comprises from about 1 wt. % to about 6 wt. % of the composition, and wherein the styrene-ethylene-butylene-styrene comprises from about 33 wt. % to about 67 wt. % of styrene.
 2. The composition of claim 1, wherein the polycarbonate comprises an isosorbide-bis-phenol A polycarbonate-C36 diacid terpolymer.
 3. The composition of claim 2, wherein the terpolymer comprises about 65 mole % isosorbide.
 4. The composition of claim 2, wherein the terpolymer comprises about 80 mole % isosorbide.
 5. The composition of claim 1, having a bio-sourced isosorbide content of at least about 60 wt. %.
 6. The composition of claim 1, having a bio-sourced isosorbide content of at least about 70 wt. %.
 7. The composition of claim 1, having a notched Izod impact strength of at least about 10 kJ/m².
 8. The composition of claim 1, having a notched Izod impact strength of at least about 15 kJ/m².
 9. The composition of claim 1, having a notched Izod impact strength of at least about 20 kJ/m².
 10. The composition of claim 1, having a notched Izod impact strength of at least 4 times that of a polycarbonate prepared from a bio-sourced isosorbide not comprising a styrene-ethylene-butylene-styrene polymer.
 11. The composition of claim 1, having a notched Izod impact strength of at least 5 times that of a polycarbonate prepared from a bio-sourced isosorbide not comprising a styrene-ethylene-butylene-styrene polymer.
 12. The composition of claim 1, having a scratch resistance similar to or greater than that of a polycarbonate prepared from a bio-sourced isosorbide not comprising a styrene-ethylene-butylene-styrene polymer.
 13. The composition of claim 1, wherein the composition does not delaminate under tensile fracture.
 14. The composition of claim 1, wherein the epoxy comprises at least about 2 wt. % of the composition.
 15. The composition of claim 1, wherein the epoxy comprises about 3 wt. % of the composition.
 16. The composition of claim 1, wherein upon exposure to heat and hydro aging the composition exhibits a color shift of less than about
 1. 17. The composition of claim 1, wherein upon exposure to heat and hydro aging the composition exhibits a color shift of less than about 0.5.
 18. The composition of claim 1, wherein upon exposure to UV aging the composition exhibits a color shift of less than about
 1. 19. The composition of claim 1, wherein upon exposure to UV aging the composition exhibits a color shift of less than about 0.5.
 20. The composition of claim 1, wherein the styrene-ethylene-butylene-styrene comprises about 67 wt. % styrene.
 21. The composition of claim 20, wherein the composition has a transparency of at least about 80%.
 22. The composition of claim 20, wherein the composition has a transparency of at least 95% of the transparency of a polycarbonate prepared from a bio-sourced isosorbide not comprising a styrene-ethylene-butylene-styrene polymer.
 23. The composition of claim 20, wherein the composition does not delaminate under tensile fracture.
 24. The composition of claim 20, wherein the epoxy comprises at least about 2 wt. % of the composition.
 25. The composition of claim 20, wherein the epoxy comprises about 3 wt. % of the composition.
 26. The composition of claim 4, having a notched Izod impact strength of at least about 10 kJ/m².
 27. The composition of claim 4, wherein the composition has a transparency of at least about 80%.
 28. The composition of claim 4, wherein the composition has a transparency of at least 95% of the transparency of a polycarbonate prepared from a bio-sourced isosorbide not comprising a styrene-ethylene-butylene-styrene polymer.
 29. A method for preparing a bio-sourced polycarbonate composition, the method comprising a step of contacting a bio-sourced isosorbide-bis-phenol A polycarbonate-C36 diacid terpolymer (Iso ter PC) with a styrene-ethylene-butylene-styrene polymer, and further comprising an additional step of contacting a styrenic epoxy with at least one of the Iso ter PC, the styrene-ethylene-butylene-styrene polymer, or a combination thereof.
 30. The method of claim 29, wherein the Iso ter PC comprises at least about 60 wt. % bio-content.
 31. The method of claim 29, wherein the Iso ter PC comprises at least about 80 wt. % bio-content.
 32. The method of claim 29, wherein the Iso ter PC comprises about 65 mol % isosorbide.
 33. The method of claim 29, wherein the Iso ter PC comprises about 80 mol % isosorbide.
 34. The method of claim 29, wherein the styrene-ethylene-butylene-styrene comprises from about 17 wt. % to about 67 wt. % styrene.
 35. The method of claim 29, wherein the styrene-ethylene-butylene-styrene comprises about 33 wt. % styrene.
 36. The method of claim 29, wherein the styrene-ethylene-butylene-styrene comprises about 67 wt. % styrene.
 37. The method of claim 29, wherein the styrene-ethylene-butylene-styrene comprises about 6 wt. % of the total composition. 